Treatment of fluidized solid catalyst



March l, 1949. R. v. SHANKLAND TREATMENT OF FLUIDIZED SOLID CATALYST 2 Sheets-Sheet 1 Filed Dec. 22, 1944 muwbl.

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R. V. SHANKLAND TREATMENT 0F FLUIDIZD'SOLID CATALYST March l, 1949.

' 2 sheets-sheet 2 Filed Dec. 22, 1944 Patented Mar. l,` 1949 TREATMENT oF FLUmrzEn soun cA'rALYs'r Rodney V. Shanklnd, Chicago, Ill., assigner to Standard Oil Company, Chicago, Ill., a corporation of Indiana Application December 22, 1944, Serial No. 569,386 wl.' 19e-sz) 'l Claims.

This invention relates to a process of hydrocarbon conversion and more particularly to a process of converting hydrocarbons by contacting with uidized solid catalysts suspended in hydro.- carbon vapors. One object of the invention is to facilitate the regeneration of the catalyst in a uidized conversion system whereby the emciency of theprocess may be increased. Another object of the invention is to increase the capacity of the hydrocarbon conversion system. Still another object of the invention is vto decrease the load on the catalyst regenerator in a conversion system where the catalyst is recycled continuously between the reaction zone andthe regeneration zone and where the regeneration is eiected by combustion of carbonaceous deposits from the catalyst. Reduction in the rate of catalyst deactivation is also an object. Other objects of the invention will become apparent from the following description thereof:

In uidized, solid catalyst hydrocarbon conversion processes, it is generally the practice to continuously or intermittently transfer partially spent catalyst from the reaction zone to a regeneration zone wherein it is brought in contact with a current of air or other oxygen-containing gas at a controlled elevated temperature usually in the range of 950 to 1200 F. In the regeneration zone the carbon-aceous deposits are removed from the catalyst by combustion and pass oli' as carbon monoxide, carbon dioxide, and water, leaving the catalyst substantially in its original active condition. The catalyst is then conducted back to the reactor where it is employed to effect the conversion of additional quantities of hydrothe air employed for the'regeneration operation. Obviously any reduction which can belinade in the amount of combustible matter conducted between the'reactor and the .regenerator Afavorably influences the economics of the process;

Irl-the prior art processes, it-:ihas heretofore been the practice to strip volatilizable Vmaterial from the spent catalyst in the stripping zone by means of stripping steamv which is caused toilow countercurrent to a stream of catalyst, thus displacing hydrocarbon vaporsv occluded or adsorbed in the catalyst. Y The steam employed in this way commonly found its way into the reactor and escaped from the reactor with the reactionproduct vapors and was condensedand nally separated from the product as water. Some o! this stripping steam, however, has been carried with the catalyst into the regenerator and it has been found that steam when allowed to gain access to the regeneration zone has had a serious deleterious effect upon the catalyst., The explanation of this phenomenon is not clear but there is some indication that in the presence of steam and oxidizing gas and at the temperatures existing in the regenerator, the aluminum oxide, silicon dioxide,

and other metal oxides of which the catalyst is composed, undergo an allotropicrearrangement concentration of steam, such as'that generated carbons generally at a conversion temperature within the range of about 850 to 1050 F.- Processes of this kind are employed in cracking of gas oil and residual oils, the reforming of low knock rating gasoline fractions, etc.

it has generally been the practice in processes of this kind to strip from the spent catalyst flowing from the reactor to the regenerator, hydrocarbon vapors absorbed on or entrained in the catalyst, thus preventing access of such volatilizable hydrocarbons to the regenerator where they would be subjected to combustion with consequent economic loss. Even more important than the economic loss of such hydrocarbon material, however, is the increased load which such combustible material imposes on the regenerator. In fact, the regeneration of the catalyst in Ia catalytic conversion system of this kind is not an inconsiderable item of expense because of the magnitude of by combustion of hydrocarbons adsorbed on the catalyst, ordinarily can be tolerated. However.

' employed.

Referring to Figure l. the hydrocarbon feed is introduced by line I0 to furnace Ilwhere it is heated and at least partially vaporized and thence discharged by line I2 leading to reactor llwhere it is brought into contact with a tluidized mass of powdered or nnely divided solidl metal .oxide catalyst maintainedv in dense, iluidized suspenthe equipment and the power required to compress u sion therein by the action'of the upfiowing vapors,

It is generaly desirable that the vapors pass upward thru the reactor with a velocity of about 1 to feet per second to maintain the catalyst in dense uid suspension by the action of hindered settling. Catalysts of high density and relatively coarse particle size require higher vapor velocities, for example velocities as high as feet per second. The catalyst employed in reactor I3 is commonly an oxide such as` silica, alumina, magnesia, zirconia, thoria or boria, and generally mixtures of two or more of these oxides. Other metal oxides may be employed alone or in combination, particularly the oxides of the Sixth Group metals, especially chromium and molybdenum, and the oxides of vanadium and copper. A typical cracking catalyst is composed of active silica, e.g. silica gel, and 1 to 20 per cent of active alumina. Another suitable catalyst is active silica in combination with to 30 per cent of calcined magnesia. Still another effective cracking catalyst is active alumina, e.g. alumina gel, and 10 to 20 per cent of boron oxide. Certain natural earth and clays may also be used as catalysts, a typical material o! this kind being known as Super Filtrol, an

acid-treated montmorilionite clay.

In general the catalyst employed in my process is most readily uidized when the particle size is maintained within a range of about 50 to- 350 mesh-although somewhat coarser and also ner particles, e. g. -40 microns may be present. It has been found that the coarser particles are more difficult to maintain in the desired iiuidized condition while the ner particles tend to become lost from the system. The density of the catalyst in reactor I3 is usually about 5 to 35 pounds per cubic foot depending upon the character of the catalyst and the vapor velocity employed. In this range of density, generally about 10 to 25 pounds per cubic foot, the catalyst suspension behaves as a liquid and can be transported thru pipes in the same manner.

In the upper part of the reactor I3 the catalyst seeks a level and overows by line I 4 into stripper I5, leaving the vapors in the top of reactor I3 with very little catalyst suspended therein. This suspension of ne catalyst, generally well below one pound per cubic foot, is referred to as the t "dilute phasey in ,the reactor. Most of this catalyst is separated from the vapors in cyclone separator I6 whence it is returned by dip leg I'l to the dense catalyst phase in the lower part of the reactor. The vapor substantially free of catalyst are conducted by vapor line I8 to fractionating tower I9 wherein heavier unconverted hydrocarbons are condensed and separated by line 20 and the gasoline vapors are withdrawn by line 2i leading to condenser 22 and thence to separator 23 lfrom which gas is discharged by vent 24 and the gasoline product is removed by line 25. It is desirable to subject this gasoline stream to stabilization before placing it on the market, propane and lighter hydrocarbons being removed by fractionation.

In catalyst stripper I5, the catalyst ows downward over a series of ballles, if desired, leaving the stripper thru valve-controlled voutlet 26 where it is rapidly dispersed in a stream of air in line 21 introduced by blower 28 and forced into regenerator 29. The density of the catalyst in the stripper may be about the same as that in the reactor, usually a little less as a result of the agitating and aerating eiect of the uplowing stripping gas. Thus a density of about 5 to 30 lbs./cu. It. may be the average in the stripper. In stripper I5 a current of stripping steam is injected at an intermediate point by line 3l flowing up thru the: stripper countercurrent to the downowing stream of catalyst and removing therefrom the major part of volatilizable hydrocarbons adsorbed on the catalyst and entrained therein. The amount of stripping steam required for this purpose is ordinarily about 6 to 20 pounds per ton of catalyst recycled. At a lower point in the stripper there is introduced by line 3| a current of inert stripping gas such as nitrogen or carbon dioxide which may be supplied by line 32, blower 33, and line 34. It is preferrf that the inert stripping gas be relatively free of water vapor and in ordinary practice spent regeneration gas, to be described hereinafter, is satisfactory. 'I'he stripping gas passes upwardly thru stripper II countercurrently to the iiow of catalyst therein and effectively sweeps from the catalyst any stripping steam occluded therein. The amount of stripping gas required for displacing steam from the catalyst is relatively small, generally about 30 to 100 cubic feet (standard conditions) per ton of catalyst. The mixture of stripping gas and stripping steam passes out thru the top of the stripper byu line leading back to the upper part of reactor I3 or is disposed oi in some other manner, as by conducting it directly to the product recovery system, e. g. at fractionator I9, although some stripping gas will go into the reactor in any case thru line I4.

The catalyst at the bottom of stripper I5 now aerated with substantially Water-free gas and in fluid form flows to the regenerator 29 where it is regenerated by combustion with air as hereinabove indicated. Spent regeneration gases pass thru cyclone separator 36 and thence are discharged by line 31 leading to Cottrell precipitator 38 where additional finely divided entrained catalyst is recovered. The spent regeneration gases o are thence discharged from the system by line 39. A portion of the spent regeneration vgas is directed thru line 40 to stripper I5 as hereinabove described. The amount of water vapor contained in this gas is small, commonly not more than 5 to 10 per cent by weight. If desired, the spent regeneration gas employed for use in stripper I5 may be specially dried by means of a desiccating agent such as calcium chloride or ignited silica gel to reduce its moisture content, although the cost of drying is not usually justied. It may also be desirable to dry the air employed for regeneration, particularly on days when the humidity is high and when the amount of water in the regenerator is near the critical concentration at which catalyst degeneration become excessive.

The regenerated catalyst in 29 is conducted by standpipe 4I to induction line I2 as hereinabove described whereby it is transferred back to the reactor for the treatment of additional hydrocarbon stock. 'Ihe catalyst in standpipe 4I may be kept in fluidized condition by the introduction of aeration gas thru valved line 42.

Figure 2 illustrates an alternative arrangement of the catalyst stripper providing for separate disposition of the steam and the stripping gas leaving the stripper. Referring to the drawing, the stripping operation is conducted in two stages, the spent catalyst from the reactor being conducted by line 50 into steam stripper 5I where it is initially stripped with a current of steam introduced at 52. The steam and hydrocarbon vapors stripped from the catalyst are discharged by line 53 whereby they are returned to the reactor or to the hydrocarbon product recovery system. Hy-

drocarbon vapors recovered in this way are not contaminated with uncondensible gases and can be readily recovered by condensation of the' steam.

The stripped catalyst passes from the bottom of I thru valve 54 into the second stage of the stripper 55 wherein it is countercurrently contacted with a current of waterfree stripping gas introduced by line 56. The upiiowing stream of gas displaces the steam from the catalyst and carries it away thru line 51 leading to the dilute catalyst phase in the top of the regenerator, to the Cottrell precipltator, to a ue or other disposal means not shown. If this gas stream containing steam is injected into the top of the regenerator, any catalyst which it may carry with it as entrainment can be recovered in the regenerator, while the Water vapor which it contains will not adversely affect the catalyst in the regenerator, since contact therewith is avoided by introducing the moisture-laden gas into the dilute catalyst phase whence it is immediately discharged from the regenerator.

Moisture-free, stripped catalyst at the base of stripper 55 passes thence to the regenerator thru valve-controlled outlet 58.

Figure 3 describes another arrangement of the two-stage stripping apparatus similar to that shown in Figure 2 except that the stripping columns 60 and 6I are placed side-by-side and the catalyst is transferred from the bottom of the ilrst stage stripper 60 by a stream of gas introduced by line 62 and carried byline 63 to the top of stripper 6I. The carrier gas escapes with the gases from the stripper by line 64 leading to the dilute catalyst phase in the top of regenerator 65.

Spent catalyst from the reactor enters the stripper 60 by line 66 where it is contacted countercurrently with a stream of steam introduced at 61. The stream of stripping steam and hydrocarbon vapors is conducted by line 68 to the hydrocarbon recovery system.

The catalyst in stripper 6| is freed of steam by countercurrent contact withsubstantially waterfree stripping gas introduced at 69, for example, spent regeneration gas withdrawn from vent line 10 by blower 1|. It is sometimes desirable to provide additional heat to the catalyst in stripper 6I to still further increase the elimination of hydrocarbonaceous matter. This may be done generation zone by countercurrently strippingA with steam, separating the major part of the steam and volatilized hydrocarbons from the said catalyst and thereafter displacing the residual steam from the stream of catalyst by countercurrently contacting it with a substantially moisture-free, inert stripping gas introduced at a low point in a downwardly moving column of said steam-stripped catalyst, separating said inert stripping gas from catalyst out of contact withv said major part of the stripping steam, then introducing the stripped, substantially moisturefree catalyst into said regeneration zone.

2. The process of claim 1 wherein the moisturefree, inert stripping gas is comprised oi spent regeneration gas discharged from said regeneration zone.

3. The process of claim 1 wherein the catalyst is maintained in a dense phase in the reaction zone below a dilute phase therein and a mixture of stripping steam and volatilized hydrocarbons removed from the catalyst in said steam-stripping operation is returned directly to the dilute phase above the reaction zone.

4. In the process of converting hydrocarbons in the presence of uidized solid catalysts of about 50 to 350 mesh wherein the catalyst in dense phase is contacted with the hydrocarbons at conversion temperature in the reaction zone until contaminated with carbonaceous deposits, after which it is conducted to a separate regeneration zone where the deposits are removed from the catalyst in dense phase by combustion with either by superheating the stripping gas supplied by line 68 by means not shown or by introducing oxygen thereinto by valved inlet 12. For this purpose air is satisfactory. The amount of oxygen required is only sufcient to raise the temperature of the catalyst by exothermic combustion of carbon by an amount of 50 to 200 or 300 F. The stripped catalyst now free of steam is carried by the regeneration air introduced atv 13 and conducted thru transfer line 14 to the regenerator 65. Spent regeneration gas is separated from catalyst in cyclone 15 before being discharged thru line 10 while the regenerated catalyst is conducted by standpipe 16 aerated with aeration gas introduced at 11 back to the reactor thru line 18 as described in connection with Fig. 1.

Having thus described my invention what I claim is:

1. In the process of converting hydrocarbons in the presence of uidized solid catalysts of about 50 to 350 mesh wherein the catalyst in dense fluid suspension is contacted with the hydrocarbons at conversion temperature in a reaction zone until contaminated with carbonaceous deposits, after which it is conducted to a sepaan upflowing oxygen-containing gas at a high temperature of about 950 to 1200 F. and the regenerated catalyst is returned to the reaction zone, the improvement comprising separating volatilizable hydrocarbons from the catalyst owing 'from said reaction zone to said regeneration zone by stripping in two successive countercurrent stages, employing steam as the stripping uid in the iirst stage and discharging said steam and volatilized hydrocarbons into the product vapors from the reaction zone, injecting a substantially moisture-free inert stripping gas into the catalyst in the second stripping stage in sufcient amount to displace residual steam from the catalyst, separating said inert gas and steam from the catalyst and introducing it at a high point in said regeneration zone out of contact with the dense catalyst phase therein, and introducing the stripped steam-free catalyst into the regeneration zone.

5. In the process of converting hydrocarbons in the presence of a iluidized solid catalyst of about 50 to 350 mesh wherein the catalyst is contacted with hydrocarbons at conversion temperature in dense uid suspension in a reaction zone until contaminated with carbonaceous deposits, after which it is conducted to a separate regeneration zone where the deposits are removed by combustion with an oxygen-containing gas at a high temperature of about 950 to 1200 F., the spent regeneration gases are separated from the catalyst and the regenerated catalyst returned to the reaction zone, the improvement comprising stripping volatilizable hydrocarbons from the catalyst owing from the reaction zone to the regeneration Zone by contacting countercurrently with steam in a rst stripping zone, removing steam and volatilized hydrocarbons from the catalyst stream, displacing rresidual steam from the catalyst in a second stripping zone by countercurrently con tacting therein with a stream of said spent regeneration gas from said regeneration zone, separating said spent regeneration gas and residual steam from said catalyst and combining them with spent regeneration gas from said regeneration zone, and transferring the substantially steam-free catalyst from said second stripping, zone to said regeneration zone in contact with oxygen therein.

6. In the process of converting hydrocarbons in the presence of iluidized solid catalysts of about 50 to 350 mesh wherein the catalyst is contacted with the hydrocarbon at conversion temperature in a reaction zone until contaminated with carbonaceous deposits, after which it is conducted to a separate regeneration zone where the deposits are removed by combustion with an oxygen-containing gas at a high temperature of about 950 to 1200 F., spent regeneration gas is discharged from said regeneration zone and the regenerated catalyst is returned to the reaction zone, the improvement comprising stripping volatilizable hy-- drocarbons from the catalyst growing from the reaction zone to the regeneration zone by contacting with 'a relatively large amount of steam, separating said steam with volatilized hydrocarbon vapors from saidk catalyst and combining them with conversion products produced in said reaction zone, displacing residual steam from the ton of catalyst recycled and the amount of stripping gas employed is about 30 to 100 cubic feet measured at standard conditions per ton of catalyst recycled.

RODNEY V. SHANKLAND.

REFERENCES CITED The following references are of record in the le of this patent:

UNITED STATES PATENTS Number Name Date 2,300,151 Hemminger Oct. 27, 1942 2,331,433 Simpson et al Oct. 12, 1943 l2,374,151 Wolk et al Apr. 17, 1945 2,377,078 Gerhold May 29, 1945 2,391,944 Carlsmith Jan. 1, 1946 2,393,839 Thomas et al Jan. 29, 1946 2,408,943 Mekler Oct. 8, 1946 2,414,002 Thomas et al Jan. 7, 1947 FOREIGN PATENTS Number Country Date 115,689 Australia Aug. 6, 1942 Certificate of Correction Patent No. 2,463,434. March l, 1949.

RODNEY V. SHANKLAND It is hereby certified that errors appear in the printed speoication of the above numbered patent requiring correction as follows:

Column 3, line 52, for vapor read vapors; column 4, line 55, for become read becomes; column 7, line 27, for growing read flowing;

and that the said Letters Patent should be read with these corrections therein that the same may conform to the record of the case in the Patent Oioe.

Signed and sealed this 9th day of August, A. D. 1949.

THOMAS F. MURPHY,

Assistant Gommissoner af Patents. 

